Honeywell EC7830A, EC7850A, RM7830A, RM7850A Installation Instructions Manual

Page 1

EC7830A, RM7830A, EC7850A, RM7850A

7800 SERIES Relay Modules

INSTALLATION INSTRUCTIONS

APPLICATION

The Honeywell EC/RM7830A and EC/RM7850A are microprocessor-based integrated burner controls for automatically fired gas, oil, or combination fuel single burner full modulation (EC/RM7850A) or on/off (EC/RM7830A) applications. The EC/RM7830A; EC/RM7850A system consists of a relay module, subbase, amplifier, and purge card. Options include keyboard display module (KDM), Personal Computer Interface, Data ControlBus Module™, remote display mounting and Combustion System Manager® Software.

Functions provided by the EC/RM7830A and EC/RM7850A include automatic burner sequencing, flame supervision, system status indication, system or self-diagnostics and troubleshooting. Text readout on the Keyboard Display Module is available in English, Spanish, Portuguese, Katakana (Japanese), French, Chinese, German, and Italian languages.

This document provides installation and static checkout instructions. Other applicable publications are: 63-2278: Q7700 Network Interface Unit Product Data. 65-0084: Q7800A,B 22-Terminal Wiring Subbase

Product Data. 65-0090: S7800A Keyboard Display Module Product Data. 65-0091: S7810A Data ControlBus Module™ Product

Data. 65-0228: S7810B Multi-Drop Switch Module Product Data. 65-0095: S7820 Remote Reset Module Product Data. 65-0097: 221729C Dust Cover Packing Instructions. 65-0102: ZM7850A Combustion System Manager®

Operating Instructions. 65-0109: R7824, R7847, R7848, R7849, R7861, R7886

Flame Amplifiers for the 7800 SERIES

Product Data. 65-0131: 221818A Extension Cable Assembly Product

Data. 65-0229: 7800 SERIES Relay Modules Checkout and

Troubleshooting Product Data.

SPECIFICATIONS

Electrical Ratings (See Tables 3A, 3B, 3C and 3D):

Voltage and Frequency:

RM7830A and RM7850A:

120 Vac (+10/-15%), 50/60 Hz (±10%).

EC7830A and EC7850A:

220/240 Vac (+10%/-15%), 50/60 Hz (±10%) Power Dissipation: 10W maximum. Maximum Total Connected Load: 2000 VA. Fusing Total Connected Load: 20A maximum, type FRN or

equivalent.

Environmental Ratings:

Ambient T emperature:

Operating: -40°F to 140°F (-40°C to +60°C). Storage: -40°F to 150°F (-40°C to +66°C).

Humidity: 85% relative humidity continuous,

noncondensing.

Vibration: 0.5G environment.

Approvals:

RM7830A and RM7850A:

Underwriters Laboratories Inc. Listed: File No. MP268,

Guide No. MCCZ. Canadian Standards Association Certified: LR9S329-3. Factory Mutual Approved: Report No. J.I.1V9A0.AF. Industrial Risk Insurers: Acceptable. Federal Communications Commission: Part 15,

Class B, Emissions.

EC7830A and EC7850A: Factory Mutual Approved. These products also comply with the following European

directives: Gas Appliance Directive: 90/396/EEC. Low Voltage Directive: 73/23/EEC. EMC Directive: 89/336/EEC. GASTEC: CE-63AP3070/1. Lloyds Register Approval.

Oil appliances:

EC7830A: DIN-5F 106/96. EC7850A: DIN-5F 107/96.

These products are approved according to EN298, “Automatic gas burner systems for gas burners and gas burning appliances with or without fans.”

Please note the following to comply with EN60730 for remote mounting of the KDM and/or remote reset module. It is necessary to provide electrical separation using insulation at least equivalent to double or reinforced insulation. This can be accomplished by either:

1. Optically isolating the communication and/or remote reset lines from the control cabinet or

2. Providing physical separation from the communication and/or remote reset lines using electrical conduit and a 204718a Remote Display Cover Assembly or other suitable enclosure that meets ip40 class of protection.

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EC7830, RM7830A,EC7850A,RM7850A 7800 SERIES RELAY MODULES

INSTALLATION

When Installing this Product…

1. Read these instructions carefully. Failure to follow them could damage the product or cause a hazardous condition.

2. Check the ratings given in the instructions and marked on the product to make sure the product is suitable for the application.

3. Installer must be a trained, experienced, flame safeguard service technician.

4. After installation is complete, check out the product operation as provided in these instructions.

WARNING

Fire or Explosion Hazard. Can cause property damage, severe injury, or death.

Carefully follow safety requirements when installing a burner control.

CA UTION

Electrical Shock Hazard or Equipment/ Control Damage. Can cause electrical shock or equipment damage.

Disconnect power supply before beginning installation.

IMPORTANT

1. Wiring connections for the relay modules are unique; refer to Fig. 3 and 4 or the appropriate Specifications for individual subbase wiring.

2. Wiring must comply with all applicable codes, ordinances and regulations.

3. Wiring must comply with NEC Class 1 (Line Voltage) wiring.

4. Loads connected to the EC/RM7830A and EC/RM7850A must not exceed those listed on the relay module label or the Specifications; see Table 1.

5. Limits and interlocks must be rated to simultaneously carry and break current to the ignition transformer, pilot valve, and main fuel valve(s).

6. All external timers must be listed or componentrecognized by authorities who have proper jurisdiction.

7. For on-off gas-fired systems, some authorities who have jurisdiction prohibit the wiring of any limit or operating contacts in series between the flame safeguard control and the main fuel valve(s).

8. Two flame detectors can be connected in parallel with the exception of C7015 Infrared Flame Detectors.

9. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, can cause interference with radio communications. It has been tested and found to comply with the limits for a Class B computing device of Part 15 of FCC rules, which are designed to provide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area can cause interference, in which case, the users, at their own expense, may be required to take whatever measures are required to correct this interference.

10. This digital apparatus does not exceed the Class B limits for radio noise for digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications.

Location

Humidity

Install the relay module where the relative humidity never reaches the saturation point. The relay module is designed to operate in a maximum 85% relative humidity continuous, noncondensing, moisture environment. Condensing moisture can cause a safety shutdown.

Vibration

Do not install the relay module where it can be subjected to vibration in excess of 0.5G continuous maximum vibration.

Weather

The relay module is not designed to be weather tight. When installed outdoors, protect the relay module in an approved weather-tight enclosure.

Mounting Wiring Subbase

1. Mount the subbase in any position except horizontally

with the bifurcated contacts pointing down. The standard vertical position is recommended. Any other position decreases the maximum ambient temperature rating.

2. Select a location on a wall, burner or electrical panel. The Q7800 can be mounted directly in the control cabinet. Be sure to allow adequate clearance for service, installation, access or removal of the relay module, expanded annunciator, KDM, flame amplifier, flame amplifier signal voltage probes, run/test switch, electrical signal voltage probes and electrical field connections.

3. For surface mounting, use the back of the subbase as a template to mark the four screw locations, then drill the pilot holes.

4. Securely mount the subbase using four no. 6 screws (not provided).

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EC7830, RM7830A,EC7850A,RM7850A 7800 SERIES RELAY MODULES

Wiring Subbase

CAUTION

Electrical Shock Hazard or Equipment Damage. Can cause electrical shock or damage equipment.

Disconnect the power supply before beginning installation.

The internal block diagram of the EC/RM7830A is shown in Fig. 1 and the internal block diagram of the EC/RM7850A is shown in Fig. 2.

1. For subbase wiring and sequence charts, refer to Fig. 3 and 4.

CONFIGURATION JUMPERS

RUN/TEST SWITCH

MICROCOMPUTER

RESET PUSHBUTTON

RELAY DRIVE CIRCUIT

ES2

6K1

3K1

RS485

SAFETY RELAY CIRCUIT

20 6

LD2

REMOTE RESET

RTLOS

STATUS LEDS

3K2

OPTIONAL KEYBOARD

DDL

DDL COMMUNICATIONS

120 VAC, 50/60 Hz POWER SUPPLY, RM7830A; 220-240 VAC, 50/60 Hz POWER SUPPLY, EC7830A. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

TO CONNECT L1 DIRECTLY TO LOS, AT LEAST ONE CONTROLLED SHUTDOWN MUST BE PROVIDED EVERY 24 HOURS.

DISPLAY MODULE

Fig. 1. Internal block diagram of EC/RM7830A (see Fig. 3 for detailed wiring instructions).

2. For remote wiring of the KDM, refer to the

Specifications for the KDM (65-0090), Network Interface Unit (63-2278), Data ControlBus Module™ (65-0091) or Extension Cable Assembly (65-0131).

3. Disconnect the power supply from the main disconnect before beginning installation to prevent electrical shock and equipment damage. More than one disconnect can be required.

4. All wiring must comply with all applicable electrical codes, ordinances and regulations. Wiring, where required, must comply with NEC Class 1 (Line Voltage) wiring.

5. For recommended wire size and type, see Table 1.

6. For recommended grounding practices, see Table 2.

L1 HOT

PLUG-IN PURGE TIMER CARD

FLAME SIGNAL

2K 3K

4K 5K

6K 7K

POWER SUPPLY

2K2 5K1

1K1

RELAY CONTACT OPEN RELAY CONTACT CLOSED

RELAY COIL FIELD WIRING INTERNAL WIRING

4K1

7K1

2K1

PLUG-IN FLAME AMPLIFIER

RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS

CONTROL POWER

F G ... 22

INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS AND LINE VOLTAGE INPUTS

USER TERMINALS

TEST JACK

SHUTTER

IGN

PV1

PV2

FAN

M15183B

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EC7830, RM7830A,EC7850A,RM7850A 7800 SERIES RELAY MODULES

HOT

RELAY DRIVE CIRCUIT

RTLOS

8K1

8K2

9K2

2K 3K

4K 5K

6K 7K 8K 9K

POWER SUPPLY

1K1

HIGH FIRE

COMMON LOW FIRE

9K1

MODULATE

PLUG-IN PURGE TIMER CARD

FLAME SIGNAL

2K2 5K1

4K1

7K1

2K1

PLUG-IN FLAME AMPLIFIER

RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS

CONTROL POWER

F G ... 22

CONFIGURATION JUMPERS

RUN/TEST SWITCH

MICROCOMPUTER

RESET PUSHBUTTON

ES1

ES3

ES2

6K1

3K1

RS485

SAFETY RELAY CIRCUIT

20 6

LD2

REMOTE RESET

STATUS LEDS

3K2

OPTIONAL KEYBOARD DISPLAY MODULE

DDL

DDL COMMUNICATIONS

120 VAC, 50/60 Hz POWER SUPPLY, RM7850A; 220-240 VAC, 50/60 Hz POWER SUPPLY, EC7850A. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

TO CONNECT L1 DIRECTLY TO LOS, AT LEAST ONE CONTROLLED SHUTDOWN MUST BE PROVIDED EVERY 24 HOURS.

Fig. 2. Internal block diagram of EC/RM7850A (see Fig. 4 for detailed wiring instructions).

TEST JACK

SHUTTER

INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS AND LINE VOLTAGE INPUTS

USER TERMINALS RELAY CONTACT OPEN RELAY CONTACT CLOSED RELAY COIL FIELD WIRING

INTERNAL WIRING

IGN

PV1

PV2

FAN

M15184B

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EC7830, RM7830A,EC7850A,RM7850A 7800 SERIES RELAY MODULES

L1 N

G 12 N 13 3 14 4 15 5 16 6 17 7 18 8 19

(L1)

9 20

10 21

F 22

FAN

LD2 PV1

IGN

ES2

LOS PV2

FLAME DETECTOR

12O VAC, 50/60 Hz POWER SUPPLY (RM7830A). 220-240 VAC, 50/60 Hz POWER SUPPLY (EC7830A). PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

SEE FLAME DETECTOR INSTRUCTIONS FOR CORRECT WIRING.

LEGEND

ALARM (NORMALLY OPEN)

PREIGNITION INTERLOCK INPUT

BURNER/BLOWER MOTOR

IGNITION LINE VOLTAGE SUPPLY LOCKOUT INPUT AIRFLOW SWITCH INPUT MAIN FUEL VALVE PILOT VALVE 1

(INTERRUPTED) PILOT VALVE 2

(INTERMITTENT) LIMITS AND BURNER

CONTROL

AL ES2 FAN IGN

L1 LOS LD2 MV PV1

Q7800

INITIATE

POWER PILOT FLAME MAIN ALARM

STANDBY

RUN

STANDBY

PRE IGNITION

PILOT STABIL.

MAIN STABIL.

IGNITION

BURNER

POSTPURGE

MAIN VALVE

LIMITS AND BURNER CONTROL CLOSED

LOCKOUT INPUT

10 sec

AIRFLOW SWITCH CHECK

PILOT VALVE

PREIGNITION INTERLOCK

OPTIONS

SAFE START CHECK

FLAME PROVING

3 sec

5 sec

1 IF ON AT CALL FOR HEAT, HOLD (120 sec). LOCK OUT IF STILL ON.

3 or 5 sec

SAFE START CHECK

IF OFF AFTER 10 SEC OF FAN, LOCK OUT.

2, 15 or 30 sec

TAKE LOCKOUT ACTION, CONTINUE POSTPURGE TIMING.

SELECT VIA ST7800A PURGE TIMER CARD.

SELECT VIA CONFIGURATION JUMPERS OR MODEL NUMBERS.

AFS CHK

2 sec

AFS CHK

DUE TO ONE EXTRA SECOND FOR SAFETY RELAY TEST, TIMING CAN VARY FROM 3 TO 4 SECONDS.

LED DISPLAY

"PREPURGE"

WAITING

FIRST SAFETY

TIME

MAIN TRIAL

TIME

OPERATING CONTROLS AND INTERLOCKS

FLAME SIGNAL

EC/RM7830A Power Burner ON/OFF, GAS or OIL Sequence

M15185B

PV2

BURNER/BLOWER MOTOR

Fig. 3. Wiring subbase and sequence chart for EC/RM7830A.

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EC7830, RM7830A,EC7850A,RM7850A 7800 SERIES RELAY MODULES

SERIES 90 FIRING RATE

G 12 N 13

FAN

LD2 PV1

IGN

FLAME DETECTOR

120 VAC, 50/60 HZ POWER SUPPLY, RM7850A; 220-240 VAC, 50/60 HZ POWER SUPPLY, EC7850A.

SEE FLAME DETECTOR INSTRUCTIONS FOR CORRECT WIRING.

3 14

(L1)

4 15 5 16 6 17 7 18 8 19 9 20

10 21

F 22

HIGH FIRE COMMON MODULATE LOW FIRE

ES2 ES1

ES3

LOS PV2

MOTORQ7800

B R

SERIES 90 CONTROLLER

B R

L1 N

ES1

ES2

ES3

FAN

IGN

LOS

LD2

PV1

PV2

EC/RM7850A Power Burner Full Modulation, GAS or OIL Sequence

LED DISPLAY

POWER PILOT FLAME MAIN ALARM

BURNER

INITIATE

STANDBY

PURGE

DRIVE

TO HIGH

WAITING

FIRE

BURNER/BLOWER MOTOR

DRIVE TO LOW FIRE

PRE

IGNITION

FIRST SAFETY TIME

PILOT

STABIL.

MAIN TRIAL TIME

MAIN STABIL.

LEGEND

ALARM (NORMALLY OPEN)

LOW FIRE SWITCH INPUT

PREIGNITION INTERLOCK INPUT

HIGH FIRE SWITCH INPUT

BURNER/BLOWER MOTOR

IGNITION LINE VOLTAGE SUPPLY LOCKOUT INPUT AIRFLOW SWITCH INPUT

MAIN FUEL VALVE

PILOT VALVE 1 (INTERRUPTED)

PILOT VALVE 2 (INTERMITTENT)

LIMITS AND BURNER CONTROL

RUN

POSTPURGE

STANDBY

OPERATING CONTROLS AND INTERLOCKS

AFS CHK

FLAME SIGNAL

MOD

HF LF

MOTOR

2 sec

OPTIONS

1 IF ON AT CALL FOR HEAT, HOLD (120 SEC). LOCK OUT IF STILL ON.

IF OFF AFTER 10 SEC OF FAN, LOCK OUT.

TAKE LOCKOUT ACTION. CONTINUE POSTPURGE TIMING.

SELECT VIA ST7800A PURGE TIMER CARD.

AFS CHK

PREIGNITION INTERLOCK

LIMITS AND BURNER CONTROL CLOSED

LOCKOUT INPUT

10 sec

SAFE START CHECK

AIRFLOW SWITCH CHECK

HF Sw

Fig. 4. Wiring subbase and sequence chart for EC/RM7850A.

PILOT VALVE

LF Switch

3 sec

3 or 5 sec 3 or 5 sec

DUE TO ONE EXTRA SECOND FOR SAFETY RELAY TEST,

TIMING CAN VARY FROM 3 TO 4 SEC. SELECTION VIA CONFIGURATION JUMPERS OR MODEL NUMBERS.

FLAME PROVING

5 sec

MAIN VALVE

1819

6 6

5 sec

SAFE START CHECK

MODHF

2, 15 or 30 sec

AFS CHK

M15186B

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EC7830, RM7830A,EC7850A,RM7850A 7800 SERIES RELAY MODULES

Table 1. Recommended Wire Sizes and Part Numbers.

Application Recommended Wire Size Recommended Part Numbers

Line voltage terminals 14, 16, or 18 AWG copper conductor, 600

KD M 22 AWG two-wire twisted pair with

Data ControlBus Module™ 22 AWG two-wire twisted pair with

Remote Reset Module 22 AWG two-wire twisted pair, insulated

Communication Interface ControlBus™ Module

13 Vdc full-wave rectified transformer power input

The KDM, Data ControlBus Module™ (for remote mounting or communications) or Communication Interface ControlBus™ Module must be wired in daisy chain configuration, 1(a)-1(a), 2(b)-2(b), 3(c)-3(c). The order of interconnection of all the devices listed above is not important. Be aware that modules on the closest and farthest end of the daisy chain configuration string require a 120 ohm (1/4 watt minimum) resistor termination across terminals 1 and 2 of the electrical connectors for connections longer than 100 feet (31 meters).

volt insulation, moisture-resistant wire.

ground, or five-wire.

for low voltage. 22 AWG two-wire twisted pair with

ground. 18 AWG wire insulated for voltages and

temperatures for given application.

Table 2. Recommended Grounding Practices.

TTW60C, THW75C, THHN90C.

Belden 8723 shielded cable or equivalent.

—

Belden 8723 shielded cable or equivalent.

TTW60C, THW75C, THHN90C.

Ground type Recommended Practice

Earth ground (subbase and relay module).

Signal ground (KDM, Data ControlBus™ Module, Communications Interface ControlBus™ Module).

7. Recommended wire routing of leadwires: a. Do not run high voltage ignition transformer wires

in the same conduit with the flame detector, Data ControlBus Module™, or Remote Reset Module wiring.

b. Do not route flame detector, Data ControlBus

Module™, or Remote Reset Module leadwires in conduit with line voltage circuits.

c. Enclose flame detector leadwires without armor

cable in metal cable or conduit.

d. Follow directions in flame detector, Data

ControlBus Module™, or Remote Reset Module Instructions.

8. The KDM is powered from a low voltage, energy limited

source. Mount the KDM outside of a control panel when it is protected from mechanical damage.

1. Use to provide a connection between the subbase and the control panel of the equipment. Earth ground must be capable of conducting enough current to blow the 20A fuse (or breaker) in the event of an internal short circuit.

2. Use wide straps or brackets to provide minimum length, maximum surface area ground conductors. If a leadwire must be used, use 14 AWG copper wire.

3. Make sure that mechanically tightened joints along the ground path are free of nonconductive coatings and protected against corrosion on mating surfaces.

Use the shield of the signal wire to ground the device to the signal ground terminals 3(c) of each device. Connect the shield at both ends of the daisy chain to earth ground.

IMPORTANT

A 13 Vdc power supply must be used any time more than one KDM is used. A maximum of two KDM, Data ControlBus™ Modules or S7810B Multi-Drop Switch Modules are allowed in any combination.

9. Maximum wire lengths: a. EC/RM7830A and EC/RM7850A leadwires: The

maximum leadwire length is 300 feet (91 meters) to terminal inputs (Control, Running/Lockout Interlock).

b. Flame Detector leadwires: The maximum flame

sensor leadwire length is limited by the flame signal strength.

c. Remote Reset leadwires: The maximum length of

wire is 1000 feet (305 meters) to a Remote Reset pushbutton.

d. Data ControlBus Module™: The maximum Data

ControlBus Module™ cable length depends on the number of system modules connected, the noise conditions and the cable used. The maximum length of all Data ControlBus Module™ interconnecting wire is 4000 feet (1219 meters).

10. Be sure loads do not exceed the terminal ratings. Refer to the label on the relay module or to the terminal ratings in Tables 3A, 3B, 3C and 3D.

Final Wiring Check

1. Check the power supply circuit. The voltage and

frequency tolerance must match those of the relay module. (A separate power supply circuit can be required for the relay module.) Add the required disconnect means and overload protection.

2. Check all wiring circuits and complete the Static Checkout in Table 4 or 5 before installing the relay module on the subbase.

3. Install the relay module.

4. Restore power to the panel.

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EC7830, RM7830A,EC7850A,RM7850A 7800 SERIES RELAY MODULES

Table 3A. RM7830A Terminal Ratings.

Terminal No. Abbreviation Description Ratings

G  Flame Sensor Ground

Earth G  Earth Ground

N  Line Voltage Common

(Neutral) 3 AL Alarm (Normally Open) 120 Vac, 1A pilot duty, 10A inrush for 5000 cycles. 4 FAN Burner/Blower Motor 120 Vac, 4A at PF = 0.5, 20A inrush. 5 L1 Line Voltage Supply (L1) 120 Vac (+10/-15%), 50/60 Hz (±10%). 6 RT Limits and Burner Control 120 Vac, 1 mA. 7 LD2 Airflow Switch Input 120 Vac, 5A. 8 PV1 Pilot Valve 1 (Interrupted) 120 Vac, 4A at PF = 0.5, 20A inrush. 9 M V Main Fuel Valve 120 Vac, 4A at PF = 0.5, 20A inrush.

10 IGN Ignition 120 Vac, 2A at PF = 0.2.

F(11)  Flame Signal 60 to 220 Vac, current limited.

16  Control Voltage 120 Vac (+10/-15%) 17 ES2 Preignition Interlock Input 120 Vac, 1A, 10A inrush for 5000 cycles.

20 LOS Lockout Input 120 Vac, 1 mA. 21 PV2 Pilot Valve 2 (Intermittent) 120 Vac, 4A at PF = 0.5, 20A inrush. 22 SHTR Shutter Shutter drive for dynamic self-check flame sensor.

See T able 2.

Honeywell has tested this output at 9.8A at PF = 0.5, 58.8A inrush for 100,000 cycles (EN298 approval does not require this test).

2000 VA maximum connected load to relay module.

Total load current excluding Burner/Boiler Motor and Firing Rate Outputs cannot exceed 5A, 25A inrush.

  

d d

Carry 5A for 250,000 cycles.

Table 3B. EC7830A Terminal Ratings.

Terminal No. Abbreviation Description Ratings

G  Flame Sensor Ground

Earth G  Earth Ground

 

N  Line Voltage Common(Neutral) 

3 AL Alarm(Normally Open) 220/230/240 Vac, 1A, 10 A inrush for 5000 cycles. 4 FAN Burner/Blower Motor 220/230/240 Vac, 4A at PF = 0.5, 20A inrush. 5 L1 Line Voltage Supply (L1) 220 to 240 Vac (+10/-15%), 50/60 Hz (±10%).

6 RT Limits and Burner Control 220/230/240 Vac, 1 mA maximum. 7 LD2 Airflow Switch Input 220/230/240 Vac, 5A. 8 PV1 Pilot Valve 1 (Interrupted) 220/230/240 Vac, 4A at PF = 0.5, 20A inrush. 9 MV Main Fuel Valve 220/230/240 Vac, 4A at PF = 0.5, 20A inrush.

10 IGN Ignition 220/230/240 Vac, 2A ignition.

c c

F(11)  Flame Signal 60 to 220 Vac, current limited.

16  Control Voltage 220/230/240 Vac, 1A, 10A inrush for 5000 cycles;

carry 5A for 250,000 cycles. 17 ES2 Preignition Interlock Input 220/230/240 Vac, 1 mA. 20 LOS Lockout Input 220/230/240 Vac, 1 mA. 21 P V2 Pilot Valve 2 (Intermittent) 220/230/240 Vac, 4A at PF = 0.5, 20A inrush.

22 SHTR Shutter Shutter drive for dynamic self-check flame sensor.

See T able 2.

2000 VA maximum connected load to relay module.

Total load current excluding Burner/Boiler Motor and Firing Rate Outputs cannot exceed 5A, 25A inrush for 250,000 cycles.

220/240 Vac to 120 Vac, 10 VA stepdown transformer (not provided) must be used to drive the shutter.

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EC7830, RM7830A,EC7850A,RM7850A 7800 SERIES RELAY MODULES

Table 3C. RM7850A Terminal Ratings.

Terminal No. Abbreviation Description Ratings

G  Flame Sensor Ground

Earth G  Earth Ground

N  Line Voltage Common(Neutral)  3 AL Alarm (Normally Open) 120 Vac, 1A, 10A inrush for 5000 cycles. 4 L1 Line Voltage Supply (L1) 120 Vac, (+10/-15%), 50/60 Hz (±10%). 5 FAN Burner/Blower Motor 120 Vac, 4A at PF = 0.5, 20A inrush. 6 RT Limits and Burner Control 120 Vac, 1 mA. 7 LD2 Airflow Switch Input 120 Vac, 5A. 8 PV1 Pilot Valve 1 (Interrupted) 120 Vac, 4A at PF = 0.5, 20A inrush. 9 MV Main Fuel Valve 120 Vac, 4A at PF = 0.5, 20A inrush.

10 IGN Ignition 120 Vac, 2A ignition.

F(11)  Flame Signal 60 to 220 Vac, current limited.

12 HI Firing Rate High Fire 120 Vac, 0.5A at PF = 0.5. 13 COM Firing Rate Common 120 Vac, 0.5A at PF = 0.5. 14 MOD Firing Rate Modulate 120 Vac, 0.5A at PF = 0.5. 15 LO Firing Rate Low Fire 120 Vac, 0.5A at PF = 0.5. 16  Alarm (normally closed) 120 Vac, 1A, 10A inrush for 5000 cycles; carry 5A for

17 ES2 Preignition Interlock Input 120 Vac, 1 mA. 18 ES1 Low Fire Switch Input 120 Vac, 1 mA. 19 ES3 High Fire Switch Input 120 Vac, 1 mA. 20 LOS Lockout Input 120 Vac, 1 mA. 21 P V2 Pilot Valve 2 (Intermittent) 120 Vac, 4A at PF = 0.5, 20A inrush. 22 SHTR Shutter Shutter drive for dynamic self-check flame sensor.

See T able 2.

2000 VA maximum connected load to relay module.

Honeywell has tested this output at 9.8A at PF = 0.5, 58.8A inrush for 100,000 cycles (EN298 approval does not require this test).

Total load current, excluding Burner/Boiler Motor and Firing Rate Outputs cannot exceed 5A, 25A inrush.

Can also be 24 Vac, 3A at PF = 0.5.

 

e e e e

250,000 cycles.

d d

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EC7830, RM7830A,EC7850A,RM7850A 7800 SERIES RELAY MODULES

Table 3D. EC7850A Terminal Ratings.

Terminal No. Abbreviation Description Ratings

G  Flame Sensor Ground

Earth G  Earth Ground

N  Line Voltage Common(Neutral) 

3 AL Alarm (Normally Open) 220/230/240 Vac, 1A, 10A inrush for 5000 cycles. 4 L1 Line Voltage Supply (L1) 220 to 240 Vac (+10/-15%), 50/60 Hz ( ±10%). 5 FAN Burner/Blower Motor 220/230/240 Vac, 4A at PF = 0.5, 20A inrush. 6 RT Limits and Burner Control 220/230/240 Vac, 1 mA. 7 LD2 Airflow Switch Input 220/230/240 Vac, 5A. 8 PV1 Pilot Valve 1 (Interrupted) 220/230/240 Vac, 4A at PF = 0.5, 20A inrush. 9 MV Main Fuel Valve 220/230/240 Vac, 4A at PF = 0.5, 20A inrush.

10 IGN Ignition 220/230/240 Vac, 2A at PF = 0.2.

F(11)  Flame Signal 136 to 220 Vac, current limited.

12 HI Firing Rate High Fire 220/230/240 Vac, 0.5A at PF = 0.5. 13 COM Firing Rate Common 220/230/240 Vac, 0.5A at PF = 0.5. 14 MOD Firing Rate Modulate 220/230/240 Vac, 0.5A at PF = 0.5. 15 LO Firing Rate Low Fire 220/230/240 Vac, 0.5A at PF = 0.5. 16  Alarm (normally closed) 220/230/240 Vac, 1A, 10A inrush for 6000 cycles;

17 ES2 Preignition Interlock Input 220/230/240 Vac, 1 mA. 18 ES1 Low Fire Switch Input 220/230/240 Vac, 1 mA. 19 ES3 High Fire Switch Input 220/230/240 Vac, 1 mA. 20 LOS Lockout Input 220/230/240 Vac, 1 mA. 21 P V2 Pilot Valve 2 (Intermittent) 220/230/240 Vac, 4A at PF = 0.5, 20A inrush. 22 SHTR Shutter Shutter drive for dynamic self-check flame sensor.

See T ab le 2.

2000 VA maximum connected load to relay module.

Total load current, excluding Burner/Boiler Motor and Firing Rate Outputs cannot exceed 5A, 25A inrush for 250,000 cycles.

Can also be 24 Vac, 3A at PF = 0.5.

220/240 Vac to 120 Vac, 10 VA stepdown transformer (not provided) must be used to drive the shutter.

carry 5A for 250,000 cycles.

 

c c

d d d d

Mounting EC/RM7830A; EC/RM7850A Relay Module

1. Mount the relay module vertically on the Q7800

Subbase, or mount horizontally with the knife blade terminals pointing down. When mounted on the Q7800A, the relay module must be in an electrical enclosure.

2. When mounting in an electrical enclosure, provide adequate clearance for servicing, installation and removal of the relay module, KDM, flame amplifier, flame amplifier signal voltage probes, electrical signal voltage probes and electrical connections.

a. Allow an additional 2 in. (51 mm) below the relay

module for the flame amplifier mounting.

b. Allow an optional 3 in. (76 mm) minimum on both

sides of the relay module for electrical signal voltage probes.

3. Make sure no subbase wiring is projecting beyond the terminal blocks. Tuck in wiring against the back of the subbase so it does not interfere with the knife blade terminals or bifurcated contacts.

IMPORTANT

Install the relay module with a plug-in motion rather than a hinge action.

4. Mount the relay module by aligning the four L shaped corner guides and knife blade terminals with the bifurcated contacts on the wiring subbase and securely tightening the two screws without def orming the plastic.

STATIC CHECKOUT

After checking all wiring, perform this checkout before installing the relay module on the wiring subbase. These tests verify that the Q7800 Wiring Subbase is wired correctly and the external controllers, limits, interlocks, actuators, valves, transformers, motors and other devices are operating properly.

WARNING

Fire or Explosion Hazard. Can cause property damage, severe injury or death.

Close all manual fuel shutoff valves before starting this test to prev ent an explosion.

66-1092—2

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EC7830, RM7830A,EC7850A,RM7850A 7800 SERIES RELAY MODULES

Use extreme care when testing the system. Line voltage is present on most terminal connections when power is on. Ensure proper selection of configuration jumpers before starting the burner operation.

CAUTION

Electrical Hazard. Can cause equipment damage.

Do not perform a dielectric test with the relay module installed. Internal surge protectors break down and conduct a current. This can cause the relay module to fail the dielectric test or destroy the internal lightning and high current protection.

1. Open the master switch before installing or removing a jumper on the subbase.

2. Before continuing to the next test, be sure to remove test jumper(s) used in the previous test.

3. Replace all limits and interlocks that are not operating properly.

Equipment Recommended

Voltmeter (1M ohm/volt minimum sensitivity) set on the 0 to 300 Vac scale and two jumper wires, No. 14 wire, insulated, 12 in. (304.8 mm) long with insulated alligator clips at both ends.

Test No. Test Jumpers Voltmeter Normal Operation

1 None 5-L2 Line voltage at terminal 5. 1. Master switch.

2 None 17-L2 Line voltage at terminal 17. Preignition interlocks. 3 5-16  Alarm (if used) turns on. Alarm.

NOTE: Disconnect horn at this time (if used).

4 5-16 2-20 Line voltage at terminal 20. Limits in Lockout Circuit. 5 5-16 2-6 Line voltage at terminal 6. 1. Recycle limits.

6 5-16

NOTE: Remove jumpers and reconnect alarm (if used).

7 5-10  Ignition spark (if ignition

8 5-8  1. Ignition spark (if ignition

Do not bypass limits and interlocks

Table 4. EC/RM7830A Static Checkout.

2-7

5-4

1. Fan (Burner Motor or Blower) starts.

2. Line voltage at terminal 7.

transformer is connected to terminal 10).

transformer is connected to terminal 8).

2. Automatic pilot valve opens (if connected to terminal 8).

NOTE: Refer to wiring diagram of

General Instructions

1. Perform all applicable tests listed in the Static

Checkout, Table 4 or 5, in the order listed.

2. Make sure all manual fuel shutoff valves are closed.

3. For each test, open the master switch and install the

jumper wire(s) between the subbase wiring terminals listed in the Test Jumpers column.

4. Close the master switch before observing operation.

5. Read the voltage between the subbase wiring terminals

listed in the Voltmeter column.

6. If there is no voltage or the operation is abnormal, check the circuits and external devices as described in the last column.

7. Check all wiring for correct connections, tight terminal screws, correct wire, and proper wiring techniques.

8. Replace all damaged or incorrectly sized wires.

9. Replace faulty controllers, limits, interlocks, actuators,

valves, transformers, motors and other devices, as required.

10. Make sure normal operation is obtained for each required test before continuing the checkout.

11. After completing each test, be sure to open the master switch and remove the test jumper(s).

system being tested.

If Operation is Abnormal ,

Check the Items Listed Below

2. Power connected to the master switch.

3. Overload protection (fuse, circuit breaker, etc.) opened the power line.

2. Burner control.

1. Fan circuit. a. Manual fan switch. b. Fan power supply,

overload protection and starter.

c. Fan.

2. Running Limits or Airflow Switch (LD2 input).

1. Watch for spark or listen for buzz. a. Ignition electrodes are clean. b. Ignition transformer is okay.

2. Listen for click or feel head of valve for activation. a. Actuator if used. b. Pilot valve.

(continued)

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EC7830, RM7830A,EC7850A,RM7850A 7800 SERIES RELAY MODULES

Table 4. EC/RM7830A Static Checkout (continued)

Test No. Test Jumpers Voltmeter Normal Operation

9 5-21  Same as test no. 8 for connections

to terminal 8. If using direct spark ignition, check the first stage fuel

Check the Items Listed Below

Same as test no. 8. If using direct spark ignition, check the first stage fuel valve(s) instead of the pilot valve.

valve(s) instead of the pilot valve.

If Operation is Abnormal ,

10 5-9  Automatic main fuel valve(s)

open(s). If using direct spark ignition on a

model with intermittent pilot on

1. Listen for and observe operation of the main fuel valve(s) and actuator(s).

2. Valve(s) and actuator(s).

terminal 21, check the optional second stage fuel valve, if used.

Final

CAUTION

Electrical Hazard. Can cause equipment damage.

After completing these tests, open the master switch and remove all test jumpers from the subbase terminals. Then remove bypass jumpers from the low fuel pressure limits (if used).

Table 5. EC/RM 7850A Static Checkout.

Test

No.

1 None 4-2 Line voltage at terminal 4. 1. Master switch.

2 None 17-2 Line voltage at terminal 17. Preignition interlocks. 3 4-16  Alarm (if used) turns on. Alarm

NOTE: Disconnect horn at this time (if used).

4 4-16 2-20 Line voltage at terminal 20. Limits in Lockout Circuit 5 4-16 2-6

6 4-16

NOTE: Remove jumpers and re-connect alarm (if used).

7 4-10 

8 4-8  1 . Ignition spark (if ignition transformer is

9 4-21 

10 4-9 

11 12-13 18-L2

12 12-13 19-L2

Test

Jumpers Voltmeter Normal Operation

Line voltage at terminal 6. 1. Recycle limits.

5-4

2-7

1. Fan (Burner Motor or Blower) starts.

2. Line voltage at terminal 7.

Ignition spark (if ignition transformer is connected to terminal 10).

connected to terminal 8).

2. Automatic pilot valve opens (if connected to terminal 8).

NOTE: Refer to wiring diagram of system

being tested.

Same as test no. 4 for connections to terminal

8. If using direct spark ignition, check the first

stage fuel valve(s) instead of the pilot valve. Automatic main fuel valve(s) opens.

If using direct spark ignition on a model with intermittent pilot on terminal 21, check the optional second stage fuel valve, if used.

Voltmeter reads line voltage, then zero volts on terminal 18 after motor starts driving open.

Firing rate motor drives open; line voltage at terminal 19 after motor is in High Fire position.

If Operation is Abnormal,

Check These Items

2. Power connected to the master switch.

3. Overload protection (fuse, circuit breaker, etc.) did not open the power line.

2. Burner control.

1. Fan circuit. a. Manual fan switch. b. Fan power supply, overload protection and

starter.

c. Fan.

2. Running limits of Airflow Switch (LD2 input).

1. Watch for spark or listen for buzz. a. Ignition electrodes are clean. b. Ignition transformer is okay.

2. Listen for click or feel head of valve for activation. a. Actuator if used. b. Pilot valve.

Same as test no. 4. If using direct spark ignition, check the first stage fuel valve(s) instead of the pilot valve.

1. Listen for and observe operation of the main fuel valve(s) and actuator(s).

2. Valve(s) and actuator(s).

1. Low Fire Start Switch.

2. Firing rate motor and transformer.

1. High Fire Purge Switch.

2. Firing rate motor and transformer.

(continued)

66-1092—2

Page 13

Test

No.

13 14-13 19-L2

14 15-13 

Final

Test

Jumpers Voltmeter Normal Operation

CAUTION

Electrical Hazard.

Can cause equipment damage.

After completing these tests, open the master switch and remove all test jumpers from the subbase terminals. Also remove bypass jumpers from the low fuel pressure limits (if used).

EC7830, RM7830A,EC7850A,RM7850A 7800 SERIES RELAY MODULES

Table 5. EC/RM 7850A Static Checkout (continued).

Firing rate motor drives closed; zero volts at terminal 19 after motor starts driving closed.

1. Raise setpoint of Series 90 controllerfiring rate motor should drive toward open.

2. Lower setpoint of Series 90 controller firing rate motor should drive toward closed.

1. Low Fire Start Switch.

2. Firing rate motor and transformer.

1. Series 90 controller.

2. Firing rate motor and transformer.

If Operation is Abnormal,

Check These Items

WARNING

Explosion hazard. Can cause serious injury or death.

Be sure all manual fuel shutoff valves are closed.

3. PURGE Period

Mounting Other System Components (Fig. 5)

Refer to the applicable specifications for mounting other system components.

PRINCIPAL TECHNICAL FEATURES

The EC/RM7830A or EC/RM7850A Relay Module provide all customary flame safeguard functions as well as significant advancements in safety, annunciation, and system diagnostics.

Safety Shutdown (Lockout) Occurs If:

4. PREIGNITION

1. INITIATE Period

a. Purge card is not installed or removed. b. Purge card is defective. c. Configuration jumpers were changed (after 200

hours of operation). d. AC line power errors, see Operation. e. Four minute INITIATE period is exceeded.

2. STANDBY Period a. Flame signal is present after 40 seconds. b. Preignition Interlock is open an accumulative time

of 30 seconds.

c. Airflow Switch feature is enabled and the Airflow

Switch is closed for 120 seconds with Limits and Burner Control closed.

d. Ignition/pilot valve/intermittent pilot valve terminal

is energized. e. Main valve terminal is energized. f. Internal system fault. g. Purge card is not installed or removed. h. Purge card is defective. i. Lockout Input opens during STANDBY.

5. SAFETY 1 PERIOD

a. Preignition Interlock opens anytime during purge. b. Flame signal detected during purge. c. High Fire Switch fails to close within five minutes

after the firing rate motor is commanded to drive to high fire position at start of purge (EC/ RM7850A).

d. Low Fire Switch fails to close within five minutes,

after firing rate motor is commanded to drive to low fire position at end of purge (EC/RM7850A).

e. Airflow Switch Input does not close within 10

seconds.

f. If Airflow Switch is disabled, there is no jumper

between terminals 6 and 7. g. Airflow Switch opens during PURGE. h. Lockout Input opens during purge. i. Ignition/pilot valve/intermittent pilot valve terminal

is energized. j. Main valve terminal is energized. k. Internal system fault. l. Purge card is removed. m. Purge card is defective.

a. Lockout Input opens during PREIGNITION. b. Airflow Switch opens during PREIGNITION. c. Preignition Interlock opens during PREIGNITION. d. Flame signal detected during PREIGNITION. e. Ignition terminal is not energized. f. Pilot valve/intermittent pilot valve terminal is

energized. g. Main valve terminal is energized. h. Internal system fault. i. Purge card is removed. j. Purge card is defective.

a. Lockout Input opens during SAFETY 1. b. Airflow Switch opens during SAFETY 1. c. Low Fire Switch opens (EC/RM7850A). d. No flame is present at the end of SAFETY 1. e. Ignition terminal is not energized. f. Pilot valve/intermittent pilot valve terminal is not

energized. g. Main valve terminal is energized. h. Internal system fault. i. Purge card is removed. j. Purge card is defective.

66-1092—2

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EC7830, RM7830A,EC7850A,RM7850A 7800 SERIES RELAY MODULES

6. PILOT STAB. PERIOD a. Lockout Input opens during PILOT STAB. b. Airflow Switch opens during PILOT STAB. c. Low Fire Switch opens (EC/RM7850A). d. No flame is present. e. Ignition terminal is energized. f. Pilot valve/intermittent pilot valve terminal is not

energized. g. Main valve terminal is energized. h. Internal system fault. i. Purge card is removed. j. Purge card is defective.

7. MAIN TRIAL PERIOD a. Lockout Input opens during MAIN TRIAL. b. Airflow Switch opens during MAIN TRIAL. c. Low Fire Switch opens (EC/RM7850A). d. No flame is present. e. Ignition terminal is energized. f. Pilot valve/intermittent pilot valve terminal is not

energized.

g. Pilot valve is energized during MAIN TRIAL

stabilization. h. Main valve terminal is not energized. i. Internal system fault. j. Purge card is removed. k. Purge card is defective.

8. RUN Period. a. No flame is present. b. Lockout Input opens. c. Ignition/interrupted pilot valve terminal is

energized. d. Main valve terminal is not energized. e. Internal system fault. f. Purge card is removed. g. Purge card is defective. h. Airflow Switch Input opens.

9. POSTPURGE Period a. Ignition/pilot valve/intermittent pilot valve terminal

is energized. b. Main valve terminal is energized. c. Internal system fault. d. Purge card is removed. e. Purge card is defective.

restarts. If the condition is not corrected and the hold condition exists for four minutes, the relay module locks out. Causes for hold conditions in the INITIATE sequence:

a. AC line dropout detection. b. AC line noise that can prevent a sufficient reading of the

line voltage inputs.

c. Low line voltage brownouts.

The INITIATE sequence also delays the burner motor starter from being energized and de-energized from an intermittent AC line input or control input.

Standby

The relay module is ready to start an operating sequence when the operating control input determines a call for heat is present. The burner switch, limits, operating limit control and all microcomputer-monitored circuits must be in the correct state for the relay module to continue into the PURGE sequence.

Normal Start-Up Purge

The relay module provides PURGE timing selectable from two seconds to thirty minutes with power applied and the operating control indicating a call for heat.

1. The Preignition Interlocks, Limits and Burner Control, Run/Test Switch, Airflow Switch Input, Lockout Input, and all microcomputer-monitored circuits must also be in the correct operating state.

2. The blower motor output, terminal 5, is powered to start the PURGE sequence. The firing rate motor is driven to the high fire position (EC/RM7850A). The PURGE timing does not begin until the Airflow Switch Input and High Fire Switch (EC/RM7850A) are both closed.

3. The Preignition Interlock Input must remain closed throughout PURGE or a safety shutdown occurs.

4. The Airflow Switch Input must close by ten seconds into PURGE or a safety shutdown occurs.

5. After the firing rate motor reaches the PURGE rate position and PURGE timing is completed, the motor drives to the low fire position (EC/RM7850A).

OPERATION

Sequence of Operation

The relay modules have the operating sequences listed below; see Fig. 3 and 4. The relay module LED provide positive visual indication of the program sequence: POWER, PILOT, FLAME, MAIN and ALARM.

Initiate

The relay module enters the INITIATE sequence when the relay module is initially powered. The relay module can also enter the INITIATE sequence if the relay module verifies voltage fluctuations of +10/-15% or frequency fluctuations of ±10% during any part of the operating sequence. The INITIATE sequence lasts for two seconds unless the voltage or frequency tolerances are not met. When not met, a hold condition is initiated and displayed on the optional KDM for at least five seconds; when met, the INITIATE sequence

66-1092—2

Ignition Trials

1. Preignition: With the firing rate motor at the low fire

position (EC/RM7850A), the ignition transformer, terminal 10, is energized for three seconds.

2. First Safety Time (SAFETY1):

a. With the firing rate motor at the low fire position

(EC/RM7850A): (1) The pilot valves and ignition transformer,

terminals 8, 10 and 21, are energized. Terminal 8 is an interrupted pilot valve and terminal 21 is an intermittent pilot valve.

(2) During SAFETY1, the Low Fire Switch Input

must be closed. If it opens, a safety shutdown occurs (EC/RM7850A).

(3) The Preignition Interlock Input is ignored

during SAFETY1, PILOT STAB., MAIN TRIAL, RUN and POSTPURGE.

b. Flame must be proven by the end of three or five

seconds to allow the sequence to continue. A safety shutdown occurs if there is no flame.

3. Pilot stabilization (PILOT STAB.): With flame proven, the ignition, terminal 10, is de-energized. The duration of this state is five seconds.

Page 15

DUST COVER

RESET BUTTON

SEQUENCE STATUS LED PANEL

PURGE TIMER

EC7830, RM7830A,EC7850A,RM7850A 7800 SERIES RELAY MODULES

WIRING SUBBASE

RUN/TEST

RELAY MODULE

CONFIGURATION JUMPERS

SWITCH

HONEYWELL

CAPTIVE MOUNTING SCREW

BURNER CONTROL

Fig. 5. EC/RM7830A and EC/RM7850A Relay Modules exploded view.

4. Main T rial (MAIN TRIAL):

a. The MAIN TRIAL time is selectable as three or

five seconds. After PILOT STAB., and with the presence of a flame, the main fuel valve, terminal 9, is powered. If a flameout occurs, the relay module locks out within one or two seconds, depending on the amplifier Flame Failure Response Time (FFRT). Thus, the second safety time is defined as MAIN TRIAL time plus the amplifier FFRT.

b. During MAIN TRIAL, the Low Fire Switch Input

must be closed (EC/RM7850A). If it opens, a safety shutdown occurs.

c. After three or five seconds of MAIN TRIAL,

terminal 8 is de-energized for main stabilization. Flame must remain proven during this fivesecond period.

FLAME AMPLIFIER

M15187A

Postpurge

The relay module (model specific) provides a two-, 15- or 30second POSTPURGE following the completion of the RUN period. The blower motor output is powered to drive all combustion products and any unburned fuel from the combustion chamber. It also supplies combustion air to burn fuel being purged from the fuel line downstream from the fuel shutoff valve.

1. The main fuel valve and the intermittent pilot valve, terminals 9 and 21, are de-energized and the firing rate motor is commanded to the low fire position (EC/RM7850A) to begin the POSTPURGE period.

2. The Preignition Interlock Input is ignored during POSTPURGE.

3. After the POSTPURGE period is completed, the relay module re-enters STANDBY.

Run

1. The firing rate motor releases to modulation.

2. The relay module is now in RUN and remains in RUN

until the controller input, terminal 6, opens, indicating that the demand is satisfied or a limit has opened.

Run/Test Switch

The Run/Test Switch is located on the top side of the relay module, see Fig. 5. The Run/Test Switch allows the burner sequence to be altered as follows:

1. In Purge Drive to High Fire position, the Run/Test Switch, when placed in the TEST position, holds in PURGE with the firing rate motor in the High Fire position (EC/RM7850A).

66-1092—2

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EC7830, RM7830A,EC7850A,RM7850A 7800 SERIES RELAY MODULES

2. In the measured PURGE sequence, the Run/Test Switch, placed in the TEST position, causes the PURGE timing to stop. The firing rate motor is in the High Fire position.

3. In Purge Drive to Low Fire position, the Run/Test Switch, when placed in the TEST position, holds the burner in PURGE with the firing rate motor in the Low Fire position (EC/RM7850A).

4. During the PILOT STAB. period, the Run/Test Switch, when placed in the TEST position, stops the timer, allowing for pilot turn-down test and other burner adjustments. This activates a 15-second flameout timer that permits pilot flame adjustment without nuisance safety shutdowns.

5. During Run, the Run/Test Switch, when placed in the TEST position, drives the firing rate motor to the Low Fire position.

IMPORTANT

When the relay module is switched to the TEST mode, it stops and holds at the next Run/Test Switch point in the operating sequence. Make sure that the Run/Test Switch is in the RUN position before leaving the installation.

SETTINGS AND ADJUSTMENTS

Selectable Site-Configurable Jumpers

The relay module has three site-configurable jumper options, see Fig. 6 and Table 6. If necessary, clip the site-configurable jumpers with side cutters and remove the resistors from the relay module. The relay module reads the settings of these configuration jumpers at startup. After 200 hours of main valve operation, the relay module locks the jumper settings into internal memory. If these jumpers are changed after the 200 hours occur, the relay module locks out. This safety function assures that the relay module cannot be modified after it is installed in a particular location.

If JR3 (Airflow Switch) is intact (no Airflow Switch), then a jumper must be installed between terminals 6 and 7. If JR3 is clipped (Airflow Switch is present), the relay module locks out if it detects a jumper between terminals 6 and 7.

SERVICE NOTE: Clipping and removing a site-configurable

jumper enhances the level of safety.

RUN/TEST SWITCH

SELECTABLE CONFIGURATION JUMPERS

M7701B

Fig. 6. Selectable site-configurable jumpers.

Table 6. Site-configurable jumper options.

Jumper Number Description Intact Clipped

JR1 First Safety Time 5 seconds 3 seconds JR2 Main Trial Time 5 seconds 3 seconds JR3 Airflow Switch No Yes

SERVICE NOTE: Clipping and removing a site-

configurable jumper enhances the level of safety .

IMPORT ANT

Clipping site-configurable jumpers after 200 hours of operation results in a nonresettable Code 110, LOCKOUT. The relay module must be replaced.

Flame Signal Measurement

Measure the flame signal at the appropriate times as defined in the applicable flame amplifier specifications.

Home and Building Control

Honeywell Inc. Honeywell Plaza P.O. Box 524 Minneapolis MN 55408-0524

66-1092—2 R. R. Rev. 8-98

66-1092—2

For further checkout and troubleshooting, see form 65-0229.

Home and Building Control

Honeywell Limited-Honeywell Limitée 155 Gordon Baker Road North York, Ontario M2H 3N7

Printed in U.S.A. on recycled paper containing at least 10% post-consumer paper fibers.

www.honeywell.com